Plant Operations Excellence

PID Consultancy & Alarm Management

PID Consultancy & Alarm Management

PID Tuning, PID Consultancy and Alarm management Services all contribute to more stable and reliable plant operation. IPCOS’ in-depth process knowledge and experience in optimizing base layer control and alarm systems will enable you to make a big step forward towards operational excellence.

PID Tuning and Consultancy

PID loops can provide a lot of stability to your plant operation. PID loops give you improved consistency in product quality, higher production rates, better energy efficiency, and improved reliability. Many PID loops are poorly tuned or configured. As a result, operators keep those loops in MANUAL most of the time. Or they “help” the PID loop in case of disturbances by manually adjusting the output of the PID loop and then putting it back into AUTO again.
IPCOS provides PID tuning services that greatly improve the performance of your base layer controllers. Our consultants review the performance of your PID loops and retune and reconfigure the loops. We do this based on process knowledge, thereby ensuring robust control. These PID tuning services can range from 3-day site activities to multi-week projects.

Our services offering includes:

Performance audits of PID loops: how well do your PID loops perform, and where are the high priority improvement opportunities?

PID tuning and redesign: we not only tune your loops, but we may also redesign your base layer control strategy to improve operational stability.

Training courses: we teach you how to tune PID loops, so you can keep improving your plant operation!

Alarm Management Services

Alarms are meant to be a crucial element of safe plant operation. An alarm indicates to an operator that something is not how it should be. Then how can it be that in so many control rooms alarms are acknowledged without any action being taken?

The answer is simple: too many alarms are generated without good reason. And if that’s the case, it’s only logical that an alarm draws less attention than it should.

IPCOS helps companies return the operation in the control room to one in which an alarm means action. We work with the customer to execute alarm management projects from start to finish. Not just in the first phases where the “low hanging fruits” are picked, but throughout the entire alarm management project. This is a cross-discipline activity, involving Operators, Process Engineers, DCS staff, and Management. IPCOS has extensive process operations optimization experience, gained from working extensively in the control room with each of these disciplines. So we’re extremely well placed to bring these disciplines together and drive the alarm management initiative to a complete success.

We lead you through all phases of an alarm management project:

Develop, adopt and maintain an Alarm Philosophy

Performing an alarm audit and analysis (Benchmarking)

Bad actor resolution

Alarm documentation and rationalization

Implementation and enforcement

Real time alarm management

Maintaining the alarm system

Contact us to inquire about a quick benchmarking activity on your alarms, and allow us to move you towards operational excellence!

Visit our Youtube channel to watch our recorded webinar on Alarm Management. Contact us to inquire about a quick benchmarking activity on your alarms, and allow us to move you towards operational excellence!